Apparatus for shaping the end of an optical fiber

ABSTRACT

An apparatus is provided for shaping an end of an optical fiber. The apparatus may include a frame and a clamp constructed to hold the optical fiber in a fixed location relative to the frame. The apparatus may further include a tip shaper supported by the frame and movable in a first direction toward and away from the clamp, and moveable in a second direction that lies in a plane transverse to the first direction to shape the end of the optical fiber when the tip shaper is placed in contact with the optical fiber. The apparatus may include an abrasive substrate which abrades the end of the fiber.

FIELD OF THE INVENTION

The present invention relates to optical fibers, and more particularly,to an apparatus for shaping an end of an optical fiber.

BACKGROUND OF INVENTION

Fiber optic systems are used in a variety of applications. In a fiberoptic system, information in the form of a light signal is transmittedbetween different portions of the fiber optic system through an opticalfiber. End faces of two optical fibers may be axially aligned and placedinto contact under a predetermined axial load to make a point-to-pointsignal connection.

To transmit the light signal through the fiber optic system, it isimportant for an end face of an optical fiber to have desired surfacecharacteristics so that the end face may interface suitably with othercomponents in the fiber optic system. An optical fiber end face thatdoes not have desired surface characteristics may result in signal lossand degraded optical performance of the fiber optic system. In somecircumstances, an optical fiber with an end surface that does not havedesired surface characteristics may render the optical fiber inoperable.

It may be desirable for the end face of an optical fiber to be smoothand/or flat. In some circumstances, it may be desirable for the end faceof the optical fiber to be square, such that the end face issubstantially perpendicular to the axis of the fiber. In othercircumstances, it may be desirable for the end face of an optical fiberto have a curved shape.

Cleaving and polishing an optical fiber are two conventional approachesto obtaining the desired surface characteristics of an optical fiber endface. Traditionally, cleaving and polishing are performed in acontrolled manufacturing environment.

In a less controlled environment, such as in a field environment, it maystill be desirable to process an end face to achieve desired surfacequalities. For example, for various types of optical fiber repair andmaintenance work, such as splicing fibers and repairing connectors, itmay be desirable to process the fiber to achieve a smooth, flat, curved,and/or square end surface as part of the repair or maintenance work.However, it may be difficult to achieve these desired optical fiber endsurface characteristics in an uncontrolled environment using knowncleaving and polishing devices.

It is thus an object of the present invention to provide an apparatusfor shaping an end of an optical fiber to provide desired surfacecharacteristics.

SUMMARY OF INVENTION

In one illustrative embodiment of the present invention, an apparatus isprovided for shaping an end of an optical fiber. The apparatus includesa frame and a clamp constructed and arranged to hold the optical fiberin a fixed location relative to the frame. The apparatus also includes atip shaper supported by the frame. The tip shaper is movable in a firstdirection toward and away from the clamp and is moveable in a seconddirection that lies in a plane transverse to the first direction toshape the end of the optical fiber when the tip shaper is placed incontact with the optical fiber.

In another illustrative embodiment, an apparatus is provided for shapingan end of an optical fiber. The apparatus includes a frame and a tipshaper supported by the frame and moveable relative to the frame toshape the end of the optical fiber when the tip shaper is placed incontact with the optical fiber. The apparatus further includes acounterweight supported by the frame. The counterweight is constructedand arranged to maintain a predetermined force between the tip shaperand the end of the optical fiber when the tip shaper is shaping the endof the optical fiber independent of the orientation of the tip shaper.

In a further illustrative embodiment, an apparatus is provided forshaping an end of an optical fiber. The apparatus includes a frame, aclamp constructed and arranged to hold the optical fiber in a fixedlocation relative to the frame, and a tip shaper supported by the frameand moveable relative to the frame to shape the end of the optical fiberwhen the tip shaper is placed in contact with the optical fiber. Theapparatus also includes a fiber support constructed and arranged tosupport an end portion of the optical fiber. The fiber support ismovable along the end portion of the optical fiber in response to thetip shaper shaping the end of the optical fiber.

In yet another illustrative embodiment, an apparatus is provided forshaping an end of an optical fiber. The apparatus includes a frame, aclamp constructed and arranged to hold an optical fiber in a fixedlocation relative to the frame, and a tip shaper supported by the frameand moveable relative to the frame to shape an end of the optical fiberwhen the tip shaper is placed in contact with the optical fiber. The tipshaper includes an abrasive substrate having at least a first region anda second region adjacent the first region, the first region having firstabrasive properties and the second region having second abrasiveproperties that are different from the first abrasive properties toprovide different shaping characteristics along the abrasive substrate.

Various embodiments of the present invention provide certain advantages.Not all embodiments of the invention share the same advantages and thosethat do may not share them under all circumstances.

Further features and advantages of the present invention, as well as thestructure of various embodiments of the present invention are describedin detail below with reference to the accompanying drawings.

BRIEF DESCRIPTION OF DRAWINGS

In the drawings, each identical or nearly identical component that isillustrated in various figures is represented by a like numeral. Forpurposes of clarity, not every component may be labeled in everydrawing.

Various embodiments of the invention will now be described, by way ofexample, with reference to the accompanying drawings, in which:

FIG. 1 is a schematic view of an apparatus for shaping an optical fiberaccording to one illustrative embodiment;

FIG. 2 is a front perspective view of an apparatus for shaping anoptical fiber according to one illustrative embodiment;

FIG. 3 is a back perspective view of the apparatus shown in FIG. 2;

FIG. 4 is a front perspective view of the linear carriage and theorbital carriage included in the apparatus shown in FIG. 2;

FIG. 5 is a back perspective view of the linear carriage and the orbitalcarriage shown in FIG. 4;

FIG. 6 is a back perspective view of the orbital carriage included inthe apparatus shown in FIGS. 2-5;

FIG. 7 is a front perspective view of the orbital carriage shown in FIG.6;

FIG. 8 is a front perspective view of the linear carriage andcounterweight included in the apparatus shown in FIGS. 2-5;

FIG. 9 is a perspective view of a cartridge for supporting an abrasivesubstrate included in the apparatus shown in FIG. 2;

FIGS. 10A-10D are schematic views of an abrasive substrate according toone illustrative embodiment;

FIG. 11 is front perspective view of the fiber support assemblyaccording to one illustrative embodiment included in the apparatus shownin FIG. 2;

FIG. 12 is an exploded view of the fiber support assembly shown in FIG.11;

FIG. 13 is a cross-sectional view of a portion of the apparatus shown inFIG. 2 illustrating the fiber support assembly shown in FIGS. 11 and 12;

FIG. 14 is a perspective view of an apparatus for shaping an opticalfiber including a housing according to one illustrative embodiment; and

FIG. 15 is a block diagram for a main processor according to oneillustrative embodiment.

DETAILED DESCRIPTION

The present invention is directed to an apparatus for shaping the endface of an optical fiber. It should be appreciated that the apparatusmay be configured in any of numerous ways, and that the presentinvention is not limited to the particular apparatus and techniquesdescribed below.

Aspects of the invention are directed to an apparatus which may shapethe fiber to achieve desired end surface characteristics. As mentionedabove, an optical fiber end face that does not have desired surfacecharacteristics may result in signal loss and degraded opticalperformance of a fiber optic system. Certain embodiments are directed toan apparatus for shaping an optical fiber to obtain an end surfacehaving one or more desired surface characteristics, including, but notlimited to a flat, smooth, curved and/or square end face.

According to one aspect of the present invention, the end of an opticalfiber to be shaped by the apparatus may be substantially bare (i.e.,where various components, such as a ferrule or terminus have beenremoved, and/or coatings have been removed or stripped from the fiber).It is also contemplated that another aspect of the present invention isdirected to an apparatus for shaping the end of an optical fiber whichincludes one or more coatings and/or components, such that shaping theend of the optical fiber may also shape portions of the coatings and/orcomponents.

As set forth in more detail below, aspects of the present invention aredirected to an apparatus which may be particularly suitable for shapingan end of an optical fiber positioned in a field environment (i.e.outside a controlled manufacturing environment), such as, but notlimited to a military or industrial environment. In one embodiments, anapparatus is particularly suitable for optical fiber repair andmaintenance work, such as, but not limited, to splicing optical fibersand repairing optical fiber connectors.

The apparatus of the present invention may include a tip shaperconfigured to shape an end of an optical fiber. The apparatus may beconfigured to place the tip shaper in contact with the fiber. Theapparatus may include a frame which supports the tip shaper and a clampto hold the optical fiber in a fixed location or position relative tothe frame.

In one embodiment, the tip shaper may be movable in a first directiontoward and away from the clamp. The tip shaper may also be movable in asecond direction that lies in a plane transverse to the first directionto shape the end of the optical fiber when the tip shaper is in contactwith the optical fiber. The optical fiber may remain in a fixed positionand the tip shaper may both move toward the optical fiber until itcontacts the fiber and the tip shaper may also move relative to theoptical fiber to shape the end of the optical fiber. In one embodiment,the first direction may include linear movement. In one embodiment, thesecond direction may include linear movement, orbital movement, or acombination of linear and orbital movement. It is to be understood thatthe tip shaper may be configured to employ other movement suitable forshaping the fiber.

The tip shaper may include an abrasive substrate that shapes the opticalfiber by abrading the end of the optical fiber. It should be recognizedthat in one embodiment, the shaping of the end of the optical fiber maybe analogous to a sanding or polishing action and the abrasive substratemay include a sandpaper-like material. The tip shaper may also include asubstrate support that supports the substrate and along which theabrasive substrate may be advanceable. The shape and rigidity of thesubstrate support may be selected based upon the desired optical fiberend face surface characteristics.

There are various factors associated with shaping an optical fiber.Factors such as the amount of force between the optical fiber and thetip shaper, the amount of time the optical fiber contacts the tipshaper, and the abrasive properties of the abrasive substrate may beadjusted to vary the amount the end of the optical fiber is shaped. Ingeneral, the greater the force between the optical fiber and the tipshaper, the greater the amount of shaping or abrading of the fiber.Similarly, the greater the time the optical fiber contacts the tipshaper, the greater the amount of shaping or abrading of the fiber.Furthermore, the more abrasive the abrasive substrate the greater theamount of shaping or abrading of the fiber. The apparatus may beconfigured to control one or more factors for shaping the fiber.

Illustrative embodiments of the apparatus for shaping an optical fibermay include a counterweight arrangement to maintain a predeterminedforce between the tip shaper and the end of the optical fiber when thetip shaper is shaping the end of the optical fiber independent of theorientation of the tip shaper or fiber. An operator may vary theorientation of the apparatus to contact and shape the end of the opticalfiber. The apparatus may, for example, contact and shape an opticalfiber having an upward facing end face, a downward facing end face, orany other potential orientation. The counterweight may operate to ensurethat a predetermined force is applied by the tip shaper against theoptical fiber regardless of the relative orientation between the tipshaper and the fiber and/or the gravitational effects on the apparatus.

Other illustrative embodiments of the present invention are directed toan apparatus for shaping an optical fiber which includes a fiber supportto support an end portion of the optical fiber. The fiber support may bemovable along the end portion of the optical fiber in response to thetip shaper advancing against the end of the optical fiber during theshaping process. In one embodiment, the optical fiber may be held by theclamp in a cantilevered relationship and the fiber support may beconfigured to provide support to the cantilevered end of the fiber.

Another aspect of the present invention is directed to an apparatus forshaping an optical fiber having a tip shaper that includes an abrasivesubstrate having regions with different abrasive properties. In oneembodiment, the abrasive substrate may include at least a first regionand a second region adjacent the first region, where the first regionmay have first abrasive properties and the second region may have secondabrasive properties that are different from the first abrasiveproperties to provide different shaping characteristics along theabrasive substrate. The abrasive properties of the abrasive substratemay vary along the length of the abrasive substrate. As discussed ingreater detail below, aspects of the present invention are directed to amulti-layered abrasive substrate having different shapingcharacteristics.

Further aspects of the invention are directed to an automated apparatusfor shaping an optical fiber. An automated apparatus may enhance theeffectiveness of the apparatus to shape an optical fiber and may help tominimize optical fiber damage which may result from operator error. Theapparatus may include one or more automated features including, but notlimited to, controlling the advancement of the abrasive substrate,controlling the movement of the tip shaper, controlling the force thetip shaper exerts against an end of an optical fiber, controlling thelength of time to shape an optical fiber, and controlling the dispensingof a fluid onto the abrasive substrate. It is contemplated that in oneembodiment, an automated apparatus is provided, such that once theoperator actuates a trigger, no further input may be required to achievean end face having desirable surface characteristics. However, it shouldbe appreciated that other embodiments of the present invention mayemploy one or more features that are not automated.

Aspects of the invention are also directed to a hand-held apparatus forshaping an optical fiber. As the use of fiber optic systems continues toincrease, there is an increasing need for a field service tool which canquickly and effectively shape an end of an optical fiber during repairand maintenance work. For example, in one embodiment, a hand-heldapparatus is provided for shaping an optical fiber such that splicingand connector repair work may be performed in a field environment. Itshould be appreciated that each embodiment of the present invention isnot limited to a hand-held device.

Turning now to the drawings, it should be appreciated that the drawingsillustrate various components and features which may be incorporatedinto one or more embodiments of the present invention. Forsimplification, several drawings may illustrate more than one optionalfeature or component. However, the present invention is not limited tothe specific embodiments disclosed in the drawings. It should berecognized that the present invention encompasses one or moreembodiments which may include only a portion of the componentsillustrated in any one figure, and/or may also encompass one or moreembodiments combining components illustrated in multiple differentdrawings, and/or may also encompass one or more embodiments notexplicitly disclosed in the drawings.

FIG. 1 illustrates a schematic view of one embodiment of an apparatus100 for shaping an optical fiber 50. In this illustrative embodiment,the apparatus 100 includes a frame 20 and a clamp 40 arranged to hold anoptical fiber 50 in a fixed location relative to the frame 20. A tipshaper 60 is supported by the frame 20 and is movable relative to theclamp 40 and the optical fiber 50 to shape the end 52 of the fiber 50.

In one embodiment, the tip shaper 60 is moveable in a first directionwhich may be linear with movement toward the clamp 40 beingsubstantially in the direction of arrow A and movement away from theclamp 40 being substantially in the direction of arrow A′. It should beappreciated that in other embodiments, the movement of the tip shaper inthe first direction may be non-linear.

In one illustrative embodiment, the tip shaper 60 is also moveable in asecond direction that lies in a plane transverse to the first directionA-A′ to shape the end 52 of the optical fiber 50 when the tip shaper 60is placed in contact with the optical fiber 50. In one embodiment,movement of the tip shaper 60 in the second direction may includeorbital movement in the B-B′ plane. It is also contemplated thatmovement of the tip shaper 60 in the second direction may include linearmovement, and may, for example include movement of the tip shaper 60 inthe direction of arrow B, in the direction of arrow B′, back and forthmovement in the direction of both arrow B and B′, or a combination oflinear and orbital movement as the invention is not so limited.

As shown, in one embodiment, the movement of the tip shaper 60 in thesecond direction is perpendicular to the first direction of movementA-A′. It should be appreciated that in other embodiments, the movementof the tip shaper 60 in the second direction may lie in a planetransverse to the first direction but not perpendicular to the firstdirection of movement.

The movement of the tip shaper 60 in the second direction shapes the endsurface of the optical fiber 50 when the tip shaper 60 is placed intoengagement with the optical fiber 50. In this regard, the tip shaper 60may abrade, grind, sand, or polish the end surface. In one embodiment,repeated contact between the abrasive substrate 70 and the end 52 of thefiber 50 may shape the end of the fiber by abrading the end face toachieve desirable surface characteristics. In one embodiment, it may bedesirable for the end face to be smooth and flat to optimize opticalperformance. In another embodiment, it may be desirable for the opticalfiber to have a curved end face to optimize optical performance.

In embodiments where the tip shaper 60 is configured to move orbitallyin the second direction, the tip shaper 60 may include an orbitalcarriage 80 coupled to the frame 20. One embodiment of an orbitalcarriage 80 is shown in greater detail in FIGS. 2 and 4-7. In thisparticular embodiment, the orbital movement of the tip shaper 60 is in aplane transverse to the axis 162 of the optical fiber.

In one illustrative embodiment, an actuator 82 such as an orbit motor,rotates a motor pulley 86 to initiate the orbital movement of thecarriage 80. A drive belt 84 may extend around the motor pulley 86coupling the motor pulley 86 to a pair of orbit drive pulleys 88 (seeFIGS. 2, 4 and 5) to rotate the drive pulleys 88. In one embodiment, theorbital carriage 80 rotates due to the center of rotation of the orbitdrive pulley assembly 80 being offset from the center of rotation of theorbital shafts 122. It should be appreciated that the above-describedcrankshaft-type mechanism is one approach to imparting orbital movementto the tip shaper 60. Other types of mechanisms and actuators apparentto one of skill in the art may be used to orbitally move the tip shaper60 relative to the frame 20 and/or the clamp 40, as the invention is notso limited.

In one embodiment, the orbital carriage 80 may include one or morecounterbalance weights 120 to reduce vibrations throughout the apparatus100 that may be generated by the orbital movement of the orbitalcarriage 80. In the embodiment illustrated in FIGS. 2-5, the orbitalcarriage 80 includes four counterbalance weights 120 with twocounterbalance weights 120 spaced apart on each end of the shafts 122.The total moment of inertia of the counterbalance weights 120 may beapproximately equal to the total moment of inertia of the orbitalcarriage 80 and the components, such as the tip shaper 60, which orbitwith the orbital carriage 80. The counterbalance weights 120 may beconfigured to rotate in the same direction as the orbital carriage 80,but 180 degrees out of phase, to counteract and balance out the movingweight of the orbital carriage 80.

In this illustrative embodiment, each counterbalance weight 120 isconfigured with a substantially half cylindrical shape. It should berecognized that the counterbalance weights 120 may be configured withother suitable shapes apparent to one of skill in the art. Furthermore,it should be recognized that not all embodiments of the presentinvention include counterbalance weights, as the invention is not solimited.

It should be appreciated that the orbital carriage 80 may be configuredto continuously rotate the tip shaper 60 in one direction. It iscontemplated that the orbital carriage 80 may be configured to rotatethe tip shaper 60 in multiple directions. For example, the orbitalcarriage 80 may rotate in one direction, such as clockwise, andthereafter rotate in another direction, such as counterclockwise.

It is also contemplated that other types of mechanisms and actuators(not shown) apparent to one of skill in the art may be used to generaterotational movement of the tip shaper 60. Furthermore, it should beappreciated that rotational and/or linear movement of the tip shaper 60is not required for each embodiment of the shaping apparatus.

In one illustrative embodiment, the optical fiber is held by clamp 40such that the end 52 of the optical fiber 50 remains in a fixed locationas the tip shaper 60 moves to shape the optical fiber 50. In oneillustrative embodiment shown in FIG. 2, the clamp 40 includes a clamplever 42 to secure the fiber in the clamp 40. The clamp 40 may hold theoptical fiber 50 at one or more locations 54 inwardly spaced from theend 52 of the optical fiber.

In one illustrative embodiment, the clamp 40 is supported by the frame20. In one embodiment, the clamp 40 may be detachably coupled to theframe 20 such that the clamp 40 and optical fiber 50 may be selectivelycoupled to the frame 20. In another embodiment, the clamp 40 may bepermanently attached to or be formed as part of the frame 20. It shouldbe appreciated that in another embodiment, the clamp 40 may be separatefrom the frame 20. For example, in one embodiment, the clamp 40 may besupported by another frame (not shown).

As shown in the illustrative embodiment, the tip shaper 60 may includean abrasive substrate 70 to shape the end 52 of the optical fiber 50.The abrasive substrate 70 may be configured to abrade the fiber 50 untilan end surface with desired surface characteristics is achieved. In thisregard, the abrasive substrate 70 may be analogous to a sandpaper-likematerial and may range from having a coarse surface to a fine surfacedepending upon the particular application. The abrasive characteristicsof the abrasive substrate 70 are discussed more below, but in general, acoarser abrasive substrate 70 may result in a rough surface and may beused to abrade a greater amount of material from the optical fiber 50.In contrast, a finer abrasive substrate 70 may result in a fine surfaceand may be used to abrade a lesser amount of material from the opticalfiber 50.

The tip shaper 60 may include at least one substrate support 72 whichmay be supported by the frame 20 to act as a backing layer for theabrasive substrate 70 as the abrasive substrate contacts and shapes thefiber. The substrate support 72 may include a support surface which isselected based upon the desired optical fiber end face surfacecharacteristics. In one embodiment, a substrate support 72 may include asubstantially rigid and flat support surface to create a flat opticalfiber end face. In one embodiment, the substantially rigid and flatsupport surface may be formed from metal, such as stainless steel. Inone embodiment, the substrate support 72 may include a non-planar orcurved surface to create a non-planar or curved optical fiber end face.In one embodiment, the support surface of the support substrate 72 maybe formed from a relatively flexible material, such as a rubber materiallike 60 durometer urethane, to shape the end face of the optical fiberto have a slightly curved configuration. In one embodiment, the fibermay be shaped to have a slightly convex end surface. As discussed below,the substrate support 72 may be removeable based upon the desired endface surface characteristics. In one embodiment, a plurality ofsubstrate supports 72 may be provided to provide different optical fibershaping characteristics and an operator may select the substrate support72 based upon the desired optical fiber end face characteristics.

In one embodiment, the abrasive substrate 70 is advanceable along atleast a portion of the substrate support 72. The abrasive substrate 70may be advanced along the substrate support 72, such as, for example, inthe direction of arrow B′, to present a new or fresh portion of theabrasive substrate 70 to the optical fiber. Once a first portion of theabrasive substrate 70 contacts and shapes the optical fiber, the firstportion of the abrasive substrate 70 may be advanced away from theoptical fiber 50 in the direction of arrow B′.

In one embodiment, it may be desirable to advance a used portion ofabrasive substrate where the abrasive particles on the surface of thesubstrate 70 begin to wear down. As discussed in greater detail below,in other embodiments, it may be desirable to advance the first portionof the abrasive substrate to present a new or fresh portion of theabrasive substrate which may have different abrasive characteristics. Itis also contemplated that the advancement of the abrasive substrate 70across the fiber 50 may abrasively shape the end of the optical fiber.Advancement of the abrasive substrate 70 along the substrate support 72may be continuous or intermittent.

In one illustrative embodiment, the abrasive substrate 70 may be storedon a first reel 90 and a second reel 92. In one embodiment, a supply offresh or unused abrasive substrate 70 is provided on the first reel 90which acts as a feed reel. As the abrasive substrate 70 is advanced fromthe first reel 90, the used portion of the abrasive substrate 70 isstored on the second reel 92 which acts as a take-up reel. In thisregard, at least a portion of the abrasive substrate 70 may be unwoundfrom the feed reel 90 as the abrasive substrate 70 advances along aportion of the substrate support 72. Once a portion of the abrasivesubstrate 70 contacts and shapes the optical fiber, that used portion ofthe abrasive substrate 70 may then be wound onto the take-up reel 92.

A drive mechanism may be provided to advance the abrasive substrate 70with respect to the substrate support 72. In one illustrativeembodiment, the drive mechanism rotates the second reel 92 in a counterclockwise direction. The rotation of the second reel 92 may also drawabrasive substrate 70 from the first reel 90 which may rotate the firstreel 90 in a counter clockwise direction. In one illustrative embodimentshown in FIGS. 6-7, the drive mechanism may include an abrasivesubstrate drive motor 130. The drive mechanism may also include a geartrain 144 to move the abrasive substrate 70 at an intermittent orconstant rate. As shown in FIG. 7, a pinch roller drive 142 may beprovided to assist in the winding of the abrasive substrate 70 onto thesecond reel 92. A pinch roller engagement lever 148 may be provided tomove the pinch roller drive 142 into contact with the abrasive substrate70 once the abrasive substrate is positioned within the apparatus 100.It should be appreciated that any suitable drive mechanism apparent toone of skill in the art may be used to advance the abrasive substrate.

The tip shaper 60 may move in the first direction toward and away fromthe clamp 40 in a variety of ways, as the invention is not so limited.In one illustrative embodiment shown schematically in FIG. 1 and ingreater detail in FIGS. 2-5 and 8, a linear carriage 110 couples the tipshaper 60 to the frame 20 to move the tip shaper 60 along the frame 20.A linear slide 114 may slideably couple the linear carriage 110 to theframe 20 such that the tip shaper 60 moves in a linear directionrelative to the frame 20 and/or clamp 40 when the carriage 110 movesalong the linear slide 114. In one embodiment, a cam actuator 112(FIG. 1) produces rotary movement which is converted into the linearmovement of the linear carriage 110 along the linear slide 114. Itshould be appreciated that other types of mechanisms and actuatorsapparent to one of skill in the art may be used to move the tip shaper60 relative to the frame 20 and/or clamp 40.

Counterweight

As indicated above, it may be desirable to configure the apparatus sothat a predetermined force may be maintained between the tip shaper 60and an optical fiber 50 during the tip shaping process regardless of theorientation of the apparatus. This may be particularly advantageous fora handheld device.

As shown in FIGS. 2 and 8, aspects of the present invention contemplatean apparatus for shaping an optical fiber 50 which include acounterweight 200 supported by the frame 20. In one illustrativeembodiment, the counterweight 200 is arranged to maintain apredetermined force between the tip shaper 60 and an end 52 of anoptical fiber 50 when the tip shaper 60 is shaping the fiber 50. Thispredetermined force may be maintained independent of the orientation ofthe tip shaper and/or the optical fiber 50.

The orientation of the apparatus may cause gravity to affect the forcebetween the tip shaper 60 and the optical fiber 50. For example, whenthe apparatus 100 is in the vertical position shown in FIG. 1 to contacta downwardly facing optical fiber end 52, gravity may decreases theforce exerted by the tip shaper due to the weight of the apparatus 100components being drawn away from the optical fiber end 52. In thisorientation, the force between the tip shaper 60 and the end 52 of theoptical fiber 50 may be lower than a desired force for shaping the fiber50. This may result in the end 52 of the fiber 50 not meeting thedesired end surface characteristics and/or it may increase the amount oftime required to shape the fiber 50.

In contrast, when the apparatus 100 is oriented in a position to contactan upwardly facing optical fiber end 52, gravity may increase the forceexerted by the tip shaper due to the weight of the apparatus 100components being pulled toward the optical fiber end 52. In thisorientation, the force between the tip shaper 60 and the end 52 of theoptical fiber 50 may be higher than a desired force for shaping thefiber 50. This may result in the end 52 of the fiber becoming damaged oreven broken.

In the illustrative embodiment, the counterweight 200 is provided toreduce the variation in the force between the tip shaper 60 and the end52 of the optical fiber 50 due to gravity. In one embodiment, thecounterweight 200 is moveable in a linear direction relative to theframe 20. As illustrated, a linear slide 202 couples the counterweight200 to the frame 20. In other embodiments, the counterweight may move ina non-linear direction, as the invention is not so limited. In oneembodiment, when the orientation of the apparatus 100 changes, thecounterweight 200 may be configured to move along the linear slide 202.

In one embodiment, the counterweight 200 may be configured to move inresponse to movement of the linear carriage 110, but in the oppositedirection, such that the counterweight 200 counteracts the weight of thelinear carriage 110. For example, in one embodiment, if the linearcarriage 110 moves 1 centimeter to the left, the counterweight may beconfigured to move 1 centimeter to the right to counteract this movementof the linear carriage 110. In this respect, the effect of gravity onthe weight of the apparatus components, such as the linear carriage 110and tip shaper 60, is reduced so that varied orientations of theapparatus will not adversely affect the predetermined shaping forcebetween the tip shaper 60 and the end 52 of the fiber.

In one illustrative embodiment, a pulley system 210 is provided tofacilitate slidable movement of the counterweight 200 relative to theframe 20. In the illustrative embodiment, the pulley system 210 couplesthe counterweight 200 to the tip shaper 60 such that the counterweightmoves when the tip shaper and linear carriage move. In one illustrativeembodiment, the pulley system 210 includes a pair of pulleys 212 coupledto the frame 20 at spaced apart locations. The pulley system 210 furtherincludes a cable 214 coupled to the counterweight 200 and extendingaround each pulley 212. Movement of the linear carriage 110 and tipshaper 60 may generate rotation of the pulleys 212 which slidably movesthe counterweight 200 relative to the frame 20 in the direction oppositethe movement of the linear carriage 110. A spring 216 may be provided onthe cable 214 to maintain the cable in tension regardless of theorientation of the apparatus.

Fiber Support

As indicated above, it may be desirable to support the optical fiberduring the shaping process. Aspects of the present invention contemplatea fiber support 140 arranged to support an end portion of the opticalfiber 50. The fiber support 140 may be moveable along the end portion ofthe fiber 50 in response to the tip shaper 60 shaping the end of theoptical fiber 50.

In one illustrative embodiment shown in FIGS. 11-13, a fiber support 140is shown in greater detail. In particular, FIGS. 11 and 12 illustrate afiber support assembly 160 in assembled and exploded views, whereas FIG.13 illustrates the fiber support assembly 160 coupled to the clamp 40.

In one illustrative embodiment, the fiber support assembly 160 includesa fiber support 140 which may be at least partially enclosed within afiber support housing 142.

The fiber support 140 is movable along an end portion 56 of the opticalfiber 50 in response to the tip shaper 60 shaping the end of the opticalfiber 50. As the tip shaper 60 contacts and abrades the fiber 50, thefiber may be worn away by the abrasion process.

In one embodiment, the fiber support 140 moves away from the tip shaper60 once the tip shaper contacts the fiber support 140. In theillustrative embodiment, the fiber support 140 is moveable in an axialdirection along the fiber axis 162, and contact by the tip shaper 60 onthe fiber support 140 moves the fiber support 140 toward and into thefiber support housing 142.

The fiber support 140 is constructed to support an end portion 56 of theoptical fiber 50. In one illustrative embodiment, the fiber support 140has an axial passage 150 adapted to receive the optical fiber 50therethrough. As shown, the fiber support may be configured to besubstantially cylindrical shaped and the axial passage 150 may extendthrough the center of the fiber support 140. In one embodiment, thefiber support 140 may act as a floating ferrule that is slidablerelative to the end portion of the optical fiber. It should beappreciated that in other embodiments, the fiber support 140 may beshaped differently as the invention is not so limited.

In one illustrative embodiment, the fiber support 140 is biased in adirection toward the tip shaper 60. As shown in FIGS. 12 and 13, aspring 144 may be provided to bias the fiber support 140 in thedirection of arrow D (FIG. 13). In a relaxed position, a portion of thefiber support 140 may extend out from the fiber support housing 142.When the tip shaper 60 contacts and shapes the end of the optical fiber50, the fiber support 140 may move along the fiber to expose the end ofthe optical fiber for shaping. When the tip shaper 60 moves away fromthe optical fiber 50, the spring 144 biases the fiber support 140 tomove in the direction of arrow D to return to the relaxed position.

In one illustrative embodiment, the fiber support housing 142 mayinclude an end cap 146 and fasteners 148 to enclose the fiber support140 within the fiber support housing 142. The end cap 146 may include anopening 152 which communicates with the opening 352 in the apparatushousing 350 as discussed in more detail below and as illustrated in FIG.14. It should be recognized that in other embodiments, a moveable fibersupport 140 may be configured differently, and may for example beincorporated into the clamp 40.

Abrasive Substrate

Aspects of the present invention are directed to the abrasive substrate70. The abrasive substrate 70 may be formed of various materials andincludes at least one abrasive surface which is configured to shape anend 52 of the optical fiber 50. In one embodiment, the abrasive surfaceis formed with an abrasive diamond film. In other embodiments, it iscontemplated that the abrasive substrate may be formed with othermaterials such as, but not limited, to silicon carbide and/or aluminumoxide.

As mentioned above, in one embodiment, the abrasive substrate 70 may bemade from a material that is similar to a sandpaper-like material, andmovement of the tip shaper 60, which includes the abrasive substrate 70,shapes or abrades the end of the optical fiber 50.

The abrasive characteristics of the abrasive substrate 70 may also varybased upon the particular application. A coarse abrasive substrate 70may produce a rougher surface and may be used when a larger amount ofmaterial is desired to be abraded from the optical fiber and a fineabrasive substrate 70 may produce a smoother surface and may be usedwhen a smaller amount of material is desired to be abraded from theoptical fiber.

In one illustrative embodiment, a coarse abrasive substrate 70 mayinclude 6 micron diamond, which is approximately equivalent to 3000grit. In one illustrative embodiment, a fine abrasive substrate 70 mayinclude 1 micron diamond, which is approximately equivalent to 14,000grit. In one illustrative embodiment, a fine abrasive substrate 70 mayinclude 0.25 micron diamond, which is approximately equivalent to100,000 grit, and in yet another embodiment, a fine abrasive substrate70 may include 0.1 micron diamond.

Aspects of the present invention are directed to an abrasive substrate70 having regions with different abrasive properties. In this respect, afirst region of the abrasive substrate 70 may contact and abrade theoptical fiber 50, and thereafter a second region of the abrasivesubstrate 70 having abrasive properties which are different from thefirst region may contact and abrade the optical fiber 50.

In one illustrative embodiment, the abrasive substrate 70 may include aplurality of regions with different abrasive properties along the lengthof the substrate 70. It is contemplated that the abrasive substrate 70may be configured to have coarse abrasive properties at one end of thesubstrate 70 and fine abrasive properties at the other end of thesubstrate 70. In this respect, it may be desirable to start off shapingthe optical fiber with a coarse substrate to remove a sufficient amountof material, while ending the shaping process with a fine substrate toachieve a smooth and/or flat end surface.

It is also contemplated that the abrasive properties of the substratemay progressively change over each region. For example, in oneembodiment, each region of the abrasive substrate 70 is progressivelymore coarse, and in another embodiment, each region of the abrasivesubstrate 70 is progressively more fine. Furthermore, it is alsocontemplated that along the length of the abrasive substrate 70 theabrasive properties of each region may vary from coarse to fine tocoarse and so on.

An abrasive substrate 70 having a plurality of regions with differentabrasive properties may be formed with a plurality of different abrasivematerials. In one embodiment, the abrasive substrate 70 may include abase substrate with a plurality of abrasive materials fixed to a topsurface of the base substrate. It is contemplated that the plurality ofabrasive materials may be fixed to the base substrate with an adhesiveat desired locations.

Turning to FIGS. 10A-10D, one illustrative embodiment of an abrasivesubstrate 300 will now be described in greater detail. In thisparticular embodiment, multiple layers of abrasive material form theabrasive substrate 300. As illustrated in FIG. 10D, the abrasivesubstrate 300 has at least a first region 340 and a second region 342adjacent the first region 340. The first region 340 has first abrasiveproperties and the second region 342 has second abrasive properties thatare different from the first abrasive properties to provide differentshaping characteristics along the abrasive substrate. As illustrated, inone embodiment, the abrasive substrate 300 may further include a thirdregion 344 adjacent the second region 342, where the third region 344has third abrasive properties which are different from the first andsecond abrasive properties to provide different shaping characteristicsalong the abrasive substrate.

It should be appreciated that it is also contemplated for the abrasivesubstrate 300 to include one or more additional regions, as the presentinvention is not limited to a particular number of regions havingdifferent abrasive properties. It should also be recognized that anabrasive substrate having a plurality of regions with different abrasiveproperties may be formed with one or more layers as the presentinvention is not so limited.

In one illustrative embodiment, the abrasive substrate 300 includes afirst layer 310 and a second layer 320 disposed over the first layer310. The second layer 320 may have a first opening 322 extendingtherethrough to expose a portion of the first layer 310. In thisparticular embodiment, the portion of the first layer 310 which isexposed through the opening 322 forms the first region 340 and at leasta portion of the second layer 320 forms the second region 342 adjacentthe first region 340.

The abrasive substrate 300 may include one or more additional layers toform additional abrasive regions, if desired. In the embodimentillustrated in FIGS. 10A-10D, the abrasive substrate 300 includes athird layer 330 which is disposed over the second layer 320. The thirdlayer 330 may have a second opening 332 extending therethrough to exposea portion of the second layer 320. In this particular embodiment, theportion of the second layer 320 which is exposed through the secondopening 332 forms the second region 342 and at least a portion of thethird layer 330 forms the third region 344 adjacent the second region342.

In one illustrative embodiment, as shown in FIGS. 10A-10D, the pluralityof regions 340, 342, 344 having different abrasive properties may berepeated along the length of the abrasive substrate 300. When theapparatus 100 is configured such that the abrasive substrate 300 isadvanced toward the optical fiber in the direction of arrow C, an end 52of the optical fiber 50 may first contact and be shaped by the thirdregion 344 of the abrasive substrate 300. Thereafter, the substrate 300may be advanced along the substrate support 72 such that the end of theoptical fiber 50 contacts and is shaped by the second region 342, whichmay be followed by the substrate 300 being advanced such that the fibercontacts and is shaped by the first region 340. After the optical fibercontacts the first region 340, the substrate 300 may continue to beadvanced in the direction of arrow C and the optical fiber may nextcontact and be shaped by another third region 344, followed by anothersecond region 342 and another first region 340. The apparatus may beconfigured to employ one or more of such cycles to shape the tip of oneoptical fiber and/or to shape the tips of a plurality of optical fibers.

In one illustrative embodiment, the third layer 330 includes a coarseabrasive surface, the second layer 320 includes a medium abrasivesurface, and the first layer 310 includes a fine abrasive surface. Thus,as the substrate 300 is advanced in the direction of arrow C, theoptical fiber is shaped by regions which go from coarse to fine. In oneillustrative embodiment, the third layer 330 may include 6 microndiamond, the second layer 320 may include 1 micron diamond and the firstlayer 310 includes 0.1 micron diamond. It should be appreciated that inother embodiments, the regions and layers of the abrasive substrate 300may be arranged differently and employ various levels of coarseness orfineness, as the invention is not so limited.

The type of material used for the abrasive substrate 300 will also varyon the type of material being shaped by the apparatus. As mentionedabove, the end of the optical fiber to be shaped by the apparatus may besubstantially bare (i.e., where various components, such as a ferrule,and coatings have been removed or stripped from the fiber), or the fibermay include one or more coatings and or components, such that shapingthe end of the optical fiber may also shape the coatings and/orcomponents. An optical fiber having various coatings and/or componentsmay require a different type of abrasive substrate material than a bareoptical fiber. In particular, an optical fiber that includes coatingsand/or other components, such as a ferrule fixed to the end of the fiber50, may require a coarse abrasive substrate to shape the end face.

It may be desirable to moisten the abrasive substrate 70 with a fluid.Various types of fluids may be used to wet the abrasive substrate 70 asthe present invention is not limited in this respect. In oneillustrative embodiment, an abrasive substrate 70 may require anactivation fluid which may transfer the abrasive substrate 70 into aslurry. In one illustrative embodiment, a coarse abrasive substrate mayrequire a lubrication fluid. In one illustrative embodiment, a fluid maybe used to clean the optical fiber after the abrasive substrate 70shapes the fiber 50. In such embodiments, the tip shaper 60 may includea fluid dispenser 94 (FIG. 1) configured to dispense a fluid to wet atleast a portion of the abrasive substrate 70 with the fluid.

In some situations, it may be desirable to remove the fluid from theabrasive substrate 70 and/or the end face 52 of the optical fiber. Forexample, a fluid may also act as a contaminant itself. Therefore,according to one embodiment, the tip shaper 60 may include a fluidcollector 98 (FIG. 1) configured to collect a portion of the dispensedfluid. In one illustrative embodiment, the fluid collector 98 mayinclude a sponge-like material that collects the fluid by absorbingfluid from the substrate into the sponge-like material.

It should be recognized that the apparatus 100 may not include a fluiddispenser 94 and/or a fluid collector 98, as the invention alsocontemplates the use of abrasive substrates 70 which do not need to bemoistened.

Automation of Shaping Apparatus

Aspects of the present invention are directed to an automated apparatusfor shaping an end of an optical fiber. An apparatus with one or moreautomated features may enhance the effectiveness of achieving an endface with desirable surface characteristics during repair and/ormaintenance work.

In one illustrative embodiment shown in FIG. 14, the apparatus 100 mayinclude a housing 350 configured to allow an operator to hold thedevice. In one embodiment, the apparatus is a handheld device so that anoperator may more easily use the apparatus in a field environment torepair an optical fiber and the housing 350 may be shaped to fit withinan operator's hand. The housing 350 may include an opening 352 which isadapted to receive an optical fiber to initiate the tip shaping processand the operator may align and insert the end 52 of the optical fiber 50into the opening 352.

In one illustrative embodiment, when the apparatus 100 is aligned withthe end of the optical fiber, an operator may actuate a trigger 354 toactuate an automatic shaping process or cycle. Once the shaping processis actuated, the operator holds the apparatus 100 until the shapingprocess is completed. The apparatus 100 may include an indicator 360,such as an LED, which signals to the operator that the process iscomplete, such that the operator will know when he/she can remove theshaping apparatus 100 from the optical fiber.

An automated device may be advantageous by allowing less skilledtechnicians to prepare fiber ends for subsequent processing. In thisregard, once the operator actuates the trigger 354, no further input maybe required to achieve an end face having desirable surfacecharacteristics.

It is contemplated that one or more processes may be automated,including, but not limited to, movement of the tip shaper 60 in thefirst direction toward and away from the clamp 40, movement of the tipshaper in the second direction in a plane transverse to the firstdirection to shape the optical fiber, advancement of the abrasivesubstrate along at least a portion of the substrate support 72, andapplication of the fluid to the abrasive substrate.

Various types of controls may be incorporated into the shaping apparatus100 to automate the processes of the apparatus. In one illustrativeembodiment shown in FIG. 15, a main processor 400 may interact with andactuate one or more controllers.

A linear carriage controller 402 may provide an actuator control signalto control the linear movement of the tip shaper 60.

An orbital carriage controller 404 may provide a rotation control signalto the orbit motor 80 (see FIG. 3) to actuate rotation of the tip shaperin response to an actuator control signal.

An abrasive substrate feed controller 406 may provide a drive controlsignal to the drive mechanism to advance the abrasive substrate alongthe substrate support 72. The abrasive substrate feed controller 406 mayprovide a drive control signal to the drive motor 130 (FIG. 6) to unwindthe abrasive substrate 70 from the first reel 90.

A fluid dispensing controller 408 may provide a fluid control signal tothe fluid dispenser 94 to control and maintain the volume and timing offluid dispensed onto the abrasive substrate 70.

An operator signaling controller 410 may be provided to inhibit theactuation of the apparatus 100 until it is positioned in a desiredlocation. In one illustrative embodiment, the apparatus may beconfigured so that it cannot be actuated until the apparatus is alignedwith an optical fiber. This may help to prevent inadvertent waste of theabrasive substrate 70. In one embodiment, a sensor may be located on theapparatus to determine whether an end of an optical fiber has beeninserted into the opening 352 in the housing 350 (see FIG. 14). If thesensor does not detect an optical fiber, the operator will be unable toactuate the automated shaping process by actuating the trigger 354.However, once the sensor detects that an optical fiber has been insertedinto the apparatus 100, the operator may initiate the automated process.In one embodiment, an indicator may be provided to signal the operatorthat he/she may actuate the process once an optical fiber has beeninserted into the opening 352 in the housing 350. It should beappreciated that various types of sensors, such as proximity sensors andoptical sensors, may be used as the present invention is not so limited.

Software or firmware may control the desired sequence of the automatedoperation of the shaping process. Although the specific sequence may beprogrammed for certain applications, the following sequence of automatedoperations is contemplated by the present invention. First, a sensor maydetect when an optical fiber is positioned within opening 352 in theapparatus housing 350. A signal may then be sent to the operator via theindicator 360, to signal the operator that the shaping process may beinitiated. Thereafter, the operator may actuate the automated cycle byactuating the trigger 354.

Once initiated, the main processor 400 may signal the tip shaper 60 toextend linearly to contact the end face of the optical fiber. The mainprocessor 400 may also initiate the orbital rotation of the tip shaper60 which may occur to shape the end of the optical fiber. If desired,the processor may also signal the dispensing of fluid onto the substrate70 at predetermined intervals. The main processor 400 may also actuateadvancement of the abrasive substrate 70 along the substrate support 72.Once the fiber is shaped with the abrasive substrate 70 to achieve thedesired surface characteristics, the main processor 400 may signal thetip shaper 60 to return to its original orbital orientation, signal thefluid dispenser 94 to cease dispensing fluid, and/or signal the tipshaper 60 to retract away from the optical fiber 50. The main processor400 may further provide a signal to cease the advancing of the abrasivesubstrate 70 and thereafter a signal may be sent to the operator via theindicator 360 to specify that the automated shaping process is completedso that the operator may remove the apparatus from the optical fiber.

It is contemplated that the apparatus 100 may be cordless and batterypowered, and both the batteries and the main processor 400 may belocated within the housing 350. However, it should be appreciated thatit is also contemplated that components may reside outside of thehousing 30 and/or that the apparatus may be powered by standard ACcurrent.

Replaceable/Detachable Components

For some applications, it may be desirable for one or more components ofthe shaping apparatus 100 to be detachable and replaceable. For example,it may be desirable to replace the abrasive substrate 70 and/or thefluid dispenser 94 after they have been exhausted without having toreplace the entire apparatus. This may be desirable to maximize the lifeof reusable components. It may also be desirable to replace thesubstrate support 72 to vary the desired optical fiber end face surfacecharacteristics.

In one illustrative embodiment shown in FIG. 9, the abrasive substrate70 may be detachable and replaceable. For example, once the supply ofthe abrasive substrate 70 provided on the first reel 90 is exhausted,the used abrasive substrate 70 may be discarded and replaced with afresh supply of abrasive substrate 70.

In the illustrative embodiment of FIG. 9, the abrasive substrate 70 maybe contained within a cartridge 96. In this particular embodiment, thecartridge 96 supports the abrasive substrate 70, the first reel 90 andthe second reel 92. In one illustrative embodiment, the cartridge 96 maybe detachably coupled to the frame 20, and may for example be detachablycoupled to the orbital carriage 80.

To insert a new abrasive substrate 70 into the apparatus, the operatormay open a portion of the apparatus 100 to remove the spent abrasivesubstrate cartridge 96 and replace it with a new abrasive substratecartridge. For example, in the embodiment illustrated in FIG. 14, thehousing 350 includes an access door 356 with a handle 358 which enablesan operator to access the cartridge 96. The replacement process may besimilar to inserting a cassette into a cassette player. It is alsocontemplated that the cartridge 96 may include features which engagewith features in the apparatus for a snap-fit. For example, as shown inthe embodiment illustrated in FIGS. 4 and 7, the orbital carriage 80 mayinclude one or more engagement clips 146 adapted to secure the cartridgein a snap-fit relationship.

In one embodiment, the support substrate 72 may be detachable andreplaceable. The type of support substrate 72 may be chosen based uponthe desired end face surface characteristics. A support surface 72having a substantially rigid and flat support surface may be used tocreate a flat optical fiber end face. A substrate support 72 having anon-planar, non-rigid, and/or curved support surface may be used tocreate a non-planar or curved optical fiber end face. In one embodiment,the support substrate 72 may be contained with the cartridge 96 and maybe replaceable when the cartridge 96 is removed from the housing 350.

In one embodiment, one or more portions of the fluid dispenser 94 may bedetachable so that when the fluid source is depleted, a new supply offluid may be added to the apparatus. It is contemplated that the fluidmay be added to a chamber of the fluid dispenser (not shown). However,it is also contemplated that the apparatus may include a detachablefluid chamber or fluid cartridge.

It should be appreciated that various embodiments of the presentinvention may be formed with one or more of the above-describedfeatures. The above aspects and features of the invention may beemployed in any suitable combination as the present invention is notlimited in this respect. It should also be appreciated that the drawingsillustrate various components and features which may be incorporatedinto various embodiments of the present invention. For simplification,some of the drawings may illustrate more than one optional feature orcomponent. However, the present invention is not limited to the specificembodiments disclosed in the drawings. It should be recognized that thepresent invention encompasses embodiments which may include only aportion of the components illustrated in any one drawing figure, and/ormay also encompass embodiments combining components illustrated inmultiple different drawing figures.

It should be understood that the foregoing description of variousembodiments of the invention are intended merely to be illustrativethereof and that other embodiments, modifications, and equivalents ofthe invention are within the scope of the invention recited in theclaims appended hereto.

1. An apparatus for shaping an end of an optical fiber, the apparatuscomprising: a frame; a clamp constructed and arranged to hold theoptical fiber in a fixed location relative to the frame; and a tipshaper supported by the frame, the tip shaper being movable in a firstdirection toward and away from the clamp, and moveable in a seconddirection that lies in a plane transverse to the first direction toshape the end of the optical fiber when the tip shaper is placed incontact with the optical fiber.
 2. The apparatus of claim 1, wherein thetip shaper comprises an abrasive substrate to shape the end of theoptical fiber and at least one substrate support that is supported bythe frame, the abrasive substrate being advanceable along at least aportion of the substrate support.
 3. The apparatus of claim 2, whereinthe at least one substrate support includes a plurality of substratesupports constructed and arranged to provide different optical fibershaping characteristics.
 4. The apparatus of claim 1, wherein the clampis supported by the frame.
 5. The apparatus of claim 4, wherein theclamp is detachably coupled to the frame.
 6. The apparatus of claim 1,wherein the tip shaper comprises an abrasive substrate to shape the endof the optical fiber, the abrasive substrate having at least a firstregion and a second region adjacent the first region, the first regionhaving first abrasive properties and the second region having secondabrasive properties that are different from the first abrasiveproperties to provide different shaping characteristics along theabrasive substrate.
 7. The apparatus of claim 2, wherein the tip shaperfurther comprises a first reel and a second reel, wherein at least aportion of the abrasive substrate is unwound from the first reel as theabrasive substrate is advanced along a portion of the substrate support,and wherein at least a portion of the abrasive substrate is wound ontothe second reel as the abrasive substrate is advanced along a portion ofthe substrate support.
 8. The apparatus of claim 7, wherein the tipshaper further comprises a cartridge which supports the abrasivesubstrate, the first reel and the second reel, and wherein the cartridgeis detachably coupled to the frame.
 9. The apparatus of claim 1, whereinmovement in the second direction includes orbital movement.
 10. Anapparatus for shaping an end of an optical fiber, the apparatuscomprising: a frame; a tip shaper supported by the frame and moveablerelative to the frame to shape the end of the optical fiber when the tipshaper is placed in contact with the optical fiber; and a counterweightsupported by the frame, the counterweight being constructed and arrangedto maintain a predetermined force between the tip shaper and the end ofthe optical fiber when the tip shaper is shaping the end of the opticalfiber independent of the orientation of the tip shaper.
 11. Theapparatus of claim 10, wherein the counterweight is moveable in a lineardirection relative to the frame.
 12. The apparatus of claim 10, furthercomprising a clamp constructed and arranged to hold the optical fiber ina fixed location relative to the frame.
 13. The apparatus of claim 12,wherein the tip shaper is movable in a first direction toward and awayfrom the clamp.
 14. The apparatus of claim 13, wherein the tip shaper ismoveable in a second direction that lies in a plane transverse to thefirst direction to shape the end of the optical fiber when the tipshaper is placed in contact with the optical fiber.
 15. The apparatus ofclaim 10, further comprising a pulley system coupling the counterweightto the tip shaper.
 16. An apparatus for shaping an end of an opticalfiber, the apparatus comprising: a frame; a clamp constructed andarranged to hold the optical fiber in a fixed location relative to theframe; a tip shaper supported by the frame and moveable relative to theframe to shape the end of the optical fiber when the tip shaper isplaced in contact with the optical fiber; and a fiber supportconstructed and arranged to support an end portion of the optical fiber,the fiber support being movable along the end portion of the opticalfiber in response to the tip shaper shaping the end of the opticalfiber.
 17. The apparatus of claim 16, wherein the fiber support has anaxial passage adapted to receive the optical fiber therethrough, thefiber support being movable in an axial direction relative to the endportion of the optical fiber.
 18. The apparatus of claim 16, wherein thetip shaper is movable in a first direction toward and away from theclamp and in a second direction that lies in a plane transverse to thefirst direction to shape the end of the optical fiber when the tipshaper is placed in contact with the optical fiber.
 19. The apparatus ofclaim 16, wherein the fiber support is biased in a direction toward thetip shaper.
 20. The apparatus of claim 16, wherein the tip shapercomprises an abrasive substrate to shape the end of the optical fiberand a substrate support that is supported by the frame, the abrasivesubstrate being advanceable along at least a portion of the substratesupport.
 21. The apparatus of claim 16, wherein the tip shaper comprisesan abrasive substrate to shape the end of the optical fiber, theabrasive substrate having at least a first region and a second regionadjacent the first region, the first region having first abrasiveproperties and the second region having second abrasive properties thatare different from the first abrasive properties to provide differentshaping characteristics along the abrasive substrate.
 22. An apparatusfor shaping an end of an optical fiber, the apparatus comprising: aframe; a clamp constructed and arranged to hold an optical fiber in afixed location relative to the frame; and a tip shaper supported by theframe and moveable relative to the frame to shape an end of the opticalfiber when the tip shaper is placed in contact with the optical fiber,the tip shaper including an abrasive substrate having at least a firstregion and a second region adjacent the first region, the first regionhaving first abrasive properties and the second region having secondabrasive properties that are different from the first abrasiveproperties to provide different shaping characteristics along theabrasive substrate.
 23. The apparatus of claim 22, wherein the abrasivesubstrate has a third region adjacent the second region, the thirdregion having third abrasive properties that are different from thefirst and second abrasive properties to provide different shapingcharacteristics along the abrasive substrate.
 24. The apparatus of claim23, wherein the abrasive substrate includes a first layer and a secondlayer disposed over the first layer, the second layer having a firstopening extending therethrough to expose a portion of the first layer,the portion of the first layer forming the first region, at least aportion of the second layer forming the second region adjacent the firstregion; and wherein the abrasive substrate further includes a thirdlayer disposed over of the second layer, the third layer having a secondopening extending therethrough to expose a portion of the second layer,the portion of the second layer forming the second region, at least aportion of the third layer forming the third region adjacent the secondregion.
 25. The apparatus of claim 22, wherein the abrasive substrateincludes a first layer and a second layer disposed over the first layer,the second layer having a first opening extending therethrough to exposea portion of the first layer, the portion of the first layer forming thefirst region, at least a portion of the second layer forming the secondregion adjacent the first region.